Method of Packaging a Flat Display Device and Package for Use in Such a Method

ABSTRACT

A method for packaging flat display products is described. The method comprises the steps of positioning at least one such product ( 10 ), e.g. an LCD product, between a first and a second thin-walled container part ( 2,3 ) and connecting these container parts to each other, so as to form a substantially closed container, surrounding the product. The thin-walled container parts are preferably molded from plastic, wherein fastening means and product information can be integrally molded therewith. Moreover, the container parts are preferable at least partly manufactured from a transparent material, allowing the product to be viewed when packaged therein.

The invention relates to a method of packaging a panel-like display device, i.e. a flat display device such as an LCD device or a plasma device. The invention also relates to packages as defined in claims 9 and 10 and to the use of such a package as defined in claim 11.

Typically, LCD products are packed in a cardboard box and sandwiched between two cushioning parts of, for instance, foamed polystyrene. These cushioning parts protect the fragile products against impact during storage, transport and further handling. The cardboard box serves to hold the cushioning parts together and to protect them against sharp objects and the like. Moreover, it enhances the stiffness and stackability of the package. The box may be sealed by means of tape, glue or staples and may be printed or otherwise provided with product information.

The known packaging method has a number of drawbacks. First, the method employs quite some packaging material, resulting in a considerable amount of waste material. Secondly, the cushioning parts are rather voluminous and, consequently, occupy much valuable space during storage and transport. Furthermore, the method is labor-intensive, because the product first needs to be enclosed between two cushioning parts, which then need to be wrapped in an outer box to be finally sealed. Moreover, once packed, the LCD products cannot be inspected easily, so that defects occurring during transport and handling are normally detected at a very late stage, i.e. when the products are unpacked by a retailer or customer.

It is an object of the invention to provide a method of packaging flat display devices, in which at least a number of the drawbacks of the known packaging method is avoided, while maintaining the advantages thereof. More particularly, it is an object of the invention to provide a packaging method, which can be accomplished in fewer manufacturing steps and is more cost-efficient.

Furthermore, it is an object of the invention to provide a packaging method with which flat display devices can be packaged compactly so that the amount of packaging material employed is reduced as compared with the conventional packaging methods.

It is another object of the invention to provide an environmental-friendly packaging method.

It is yet another object of the invention to provide a packaging method wherein defects in the packaged products can be detected at an early stage, preferably as soon as they occur.

These and other objects are at least partly achieved with the packaging method according to the invention, as defined in claim 1.

It has surprisingly been found that a package featuring good stiffness and stackability as well as ample protection against shocks and the like, which is normally provided by the combination of the outer box and the cushioned parts, can be obtained by enclosing a flat display device, i.e. a panel-like display device such as an LCD product, between two thin-walled box-like container parts and by moving these thin-walled container parts to each other and connect them together so as to form a substantially closed container. Additionally, the reduced number of packaging parts may simplify logistics and assembly, resulting in lower costs. Moreover, the thin-walled construction of the container parts requires a considerably smaller amount of packaging material than the known packaging methods, which does not only result in less waste material after use, but also in a more compact package and less volume and weight to be transported, ultimately leading to a reduction of transportation and handling costs.

In this document, the term “display device” is to be interpreted to encompass all flat display products that comprise at least one display screen as the main component. Such products may additionally comprise other auxiliary components, such as electronics, an encasing or the like, to support functioning of the display screen. The products may be marketed in the form of television sets, monitors or components of other apparatus, such as laptops. The term “thin-walled” is to be understood to refer to walls having a relatively small thickness in relation to their other dimensions. The wall thickness may vary, for instance, from a few tenths of a millimeter up to several millimeters, depending on the overall size of the display device to be packaged.

In a preferred embodiment, a packaging method according to the invention is defined by the features of claim 2. By using a transparent or translucent packaging material for at least part of the package, the product will remain visible in its packaged state, allowing detection of defects at an early stage, i.e. before delivery to a customer, and this without having to open the package. Thus, quality can be monitored and guaranteed and money can be saved on repair costs and unnecessary transport of prematurely damaged goods. Moreover, the fact that it is at least partly transparent renders the package suitable as a display package for presenting the product to a customer. Consequently, after arrival at a selling point, the products do not need to be unpacked or repacked, which may save much work and material.

In a further elaboration, the method according to the invention may employ recyclable material for manufacturing the thin-walled container parts. This will render the packaging method even friendlier for the environment.

In a further preferred embodiment, a method according to the invention is defined by the features of claim 4. On the one hand, inwardly protruding supporting means may increase the stiffness of the thin-walled container parts and, on the other hand, act as supporting means, spacing the display device from the container walls and protecting it against external shocks by damping or completely absorbing such shocks.

The thin-walled container parts are preferably manufactured of a synthetic material, as defined by the features of claim 5. Synthetic material, or plastic, is relatively light and inexpensive and is widely available in many types and colors, while it can be recycled and made impermeable to gas and/or liquid. Moreover, plastic can be easily manufactured, notably by means of die-casting or injection molding, offering great freedom of design. Additionally, in such manufacturing techniques, the above-mentioned supporting means and/or product information can be integrally molded in the container parts. Such information can be molded in relief or by in-mould labeling and obviates the need for a separate printing or labeling step, thereby contributing to a packaging method which is even further optimized.

In a highly preferred embodiment, a method according to the invention is defined by the features of claim 7. The shock-absorbing properties of the package can be further improved by manufacturing the thin-walled container parts, or at least portions thereof, of a material having a high damping coefficient such as natural or synthetic rubber. Such damping material is preferably used for at least those parts of the container that are in direct contact with the display device, such as the supporting means.

The first and second container parts may be connected to each other by means of, for instance, tape, glue or (hot-)sealing techniques. However, in a preferred embodiment, as defined by the features of claim 8, the thin-walled container parts are provided with fastening means, preferably integrally manufactured therewith. The fastening means may be known per se. These integrated fastening means may facilitate assembly of the package even further, as the container parts can be simply connected to each other by bringing the fastening means into interlocking engagement. This can be done without special equipment, skills or supply of additional fastening materials, such as the above-mentioned glue, tape or staples, which in practice tend to complicate logistics and introduce the risk of contaminating or damaging the product.

The invention also relates to a package for a flat display device, comprising two thin-walled plastic box-like container parts, which together form a substantially closed container for enclosing at least one such device. The invention further relates to the use of such a package for transport, storage and/or display of a flat display product and consequently also relates to a package provided with such a product.

Further advantageous embodiments of a packaging method, package and use thereof according to the invention are set forth in the dependent claims.

The invention will hereinafter be explained with reference to the single FIGURE, which is an exploded view of an embodiment of a package according to the invention.

The package 1 in the illustrated embodiment comprises a thin-walled first container part 2 formed from a bottom 4, surrounded by a circumferential wall 5 and having an open top side 6, and a thin-walled second container part 3 formed from a top 8, surrounded by a circumferential wall 7 and having an open bottom side 9. Both container parts are thus box-shaped and have one open side. The container parts 2, 3 can be injection-molded from e.g. a synthetic material, or plastic. In the illustrated embodiment, the second container part 3 is provided with product information 12, which may have been integrally molded in relief or by in-mould labeling. At least one of the parts 2, 3 is preferably manufactured of a transparent plastic, so that, once enclosed in the container parts 2, 3, a panel-like display device 10—hereinafter also called product 10—can be viewed and inspected from the outside. The flat product 10 may be any display device having display cells, such as an LCD device, a foil display, a plasma display, etc.

The open top 6 and bottom 9 of the respective first and second container parts 2, 3 have matching geometries, so that the container part 3 can be mounted on top of the first container part 2 so as to form a closed container or housing wherein the circumferential edges of the first and second container parts 2, 3 may abut each other or slightly overlap. To hold the parts 2, 3 in said closed state, these parts 2, 3 may be provided with fastening means near their respective circumferential edges. Such fastening means may comprise, for instance, resilient click fingers known per se or a mating groove and ridge known per se, which can be integrally molded in the container parts 2, 3. The depicted embodiment is provided with taps 17 a and mating tap-holes 17 b as fastening means. The taps 17 a extend inwardly and have inclined gliding faces. Of course, other or additional fastening means may be used, such as tape, glue, staples or sealing techniques.

In the illustrated embodiment, the first and second container parts 2, 3 have an outer shape that substantially conforms to the contour of the product 10 to be packaged. Consequently, the packaged product will occupy only slightly more space than the unpacked product 10. Alternatively, the container parts 2, 3 may have any other shape, for instance, a rectangular outer shape, to render the package better stackable and/or stiffer.

The inner sides of the container walls 4, 5, 7, 8 may be provided with inwardly extending protrusions 15, such as ribs. This is schematically illustrated, in dotted lines, for wall 5 of the first container part 2. These protrusions 15 can be integrally formed with the container parts 2, 3 and may be designed to reinforce the thin walls 4, 5, 7, 8 thereof so as to enhance the stiffness of the package 1. Additionally, some or all of these protrusions 15 may serve as supporting means for the product 10, and may engage the product 10 at specific predetermined locations so as to secure the product 10 in the package 1, sufficiently spaced from the inner container walls. The supporting means are preferably designed to absorb or at least damp external shocks and prevent the product 10 from being exposed to detrimental vibrations. To improve their shock absorption, the protrusions 15 may be made of a material having a high damping characteristic, such as natural or synthetic rubber. Additionally or alternatively, the geometry of the protrusions 15 may be adapted so as to feature a desired dynamic stiffness, said stiffness influencing the frequency and amplitude of the vibrations being transferred to the product 10 in response to an external shock. Furthermore, the protrusions 15 may be configured so as to form compartments for accommodating a series of products 10.

The package 1 described above can be used as follows. The bottom part of the product 10 is inserted in the first container part 2, while the protrusions 15 may guide the product 10 and ensure its correct positioning. Subsequently, the opposite top end of the product 10 is covered with the second container part 3, which is connected to the first container part 4, by means of the integrated fastening means, thereby establishing a closed housing for the product 10. The package 1 is now ready for transport. By virtue of the transparency of at least one of the container parts 2, 3, the product 10 can be monitored throughout the transport process. If defects are detected, the package 1 can be singled out from the rest, so that unnecessary transportation costs are precluded and the product does not reach a customer. Once it has arrived at a distribution or selling point, the product 10 can be displayed in its package 1 on a display shelf, without the need to unpack it.

It is to be noted that the package described above represents only one example of a package according to the invention. Many variations are feasible within the scope of the invention. For instance, the first and second container parts may be connected by means of a hinge and/or injection-molded together. The container parts may also be made from different materials, for instance, laminated cardboard, preferably provided with one or more transparent windows. It will be evident that the package may be made in different colors so as to give it a more appealing appearance. These and other comparable variations are understood to be within the scope of the invention as outlined by the claims. 

1. A method of packaging a panel-like display device, the method comprising the steps of positioning at least one such device (10) between a first and a second thin-walled box-like container part (2, 3) and connecting these container parts (2, 3) to each other so as to form a substantially closed container surrounding said at least one device (10).
 2. A method as claimed in claim 1, wherein at least a portion of at least one of the container parts (2, 3) is manufactured of a transparent or translucent material for viewing the packaged device (10) from the outside.
 3. A method as claimed in claim 1, wherein the thin-walled container parts (2, 3) are manufactured of a recyclable material.
 4. A method as claimed in claim 1, wherein the thin-walled container parts (2, 3) are manufactured with inwardly protruding supporting means (15) for supporting and securing the display device (10) in the container (2, 3).
 5. A method as claimed in claim 1, wherein the thin-walled container parts (2, 3) are manufactured from a synthetic material, or plastic, for example, by means of die-casting or injection molding.
 6. A method as claimed in claim 5, wherein product-related information (12) is integrally molded in the or each thin-walled container part (2, 3).
 7. A method as claimed in claim 1, wherein at least a portion of the thin-walled container parts (2, 3) is manufactured from a material having good shock-absorbing characteristics, i.e. a high damping coefficient.
 8. A method as claimed in claim 1, wherein the first and second thin-walled container parts (2, 3) are connected to each other via fastening means, which are integrally formed in the respective container parts (2, 3).
 9. A package (1) for a flat display device, comprising at least two plastic, thin-walled box-like container parts (2, 3), which together form a substantially closed container for surrounding said flat display device (10).
 10. A package as claimed in claim 9, provided with at least one flat display device (10).
 11. Use of a thin-walled plastic container for packaging at least one flat display device (10), in which container the display device can be stored, transported and/or displayed. 